DuraDrive 4-30

Wire Feeder

Instruction Literature
ESAB Item No. 0558001911 - DuraDrive 4-30

F15-635-H 06 / 2008
 Be sure this information reaches the operator.
You can get extra copies through your supplier.

caution
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting equipment, we urge
you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain
this equipment. Do NOT attempt to install or operate this equipment until you have read
and fully understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read the Safety Precautions be-
fore installing or operating this equipment.

USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompa-
nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-
tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-
diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser-
vice facility designated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

 TABLE OF CONTENTS

SECTION SECTION PAGE

1 DESCRIPTION ............................................................................................................................................................................17

2 INSTALLATION ............................................................................................................................................................................25

3 OPERATION ............................................................................................................................................................................29

4 MAINTENANCE ............................................................................................................................................................................33

5 TROUBLESHOOTING ............................................................................................................................................................................35

6 REPLACEMENT PARTS........................................................................................................................................................................... 39
TABLE OF CONTENTS

4
 safety precautions
1.0 Safety Precautions
WARNING: These Safety Precautions are for
your protection. They summarize precaution-
ary information from the references listed in
Additional Safety Information section. Before
performing any installation or operating procedures,
be sure to read and follow the safety precautions listed
below as well as all other manuals, material safety data
sheets, labels, etc. Failure to observe Safety Precautions
can result in injury or death.
PROTECT YOURSELF AND OTHERS --
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation
and can injure skin and eyes. Hot metal can cause
burns. Training in the proper use of the processes
and equipment is essential to prevent accidents.
Therefore:
1. Always wear safety glasses with side shields in any
work area, even if welding helmets, face shields,
and goggles are also required.
2. Use a face shield fitted with the correct filter and
cover plates to protect your eyes, face, neck, and
ears from sparks and rays of the arc when operat-
ing or observing operations. Warn bystanders not
to watch the arc and not to expose themselves to
the rays of the electric-arc or hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-
sleeve shirt, cuffless trousers, high-topped shoes,
and a welding helmet or cap for hair protection,
to protect against arc rays and hot sparks or hot
metal. A flameproof apron may also be desirable
as protection against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, or pockets. Sleeves and collars should
be kept buttoned, and open pockets eliminated
from the front of clothing.
5. Protect other personnel from arc rays and hot
sparks with a suitable non-flammable partition or
curtains.
6. Use goggles over safety glasses when chipping
slag or grinding. Chipped slag may be hot and can
fly far. Bystanders should also wear goggles over
safety glasses.
5
1.1 Safety - English
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot
slag or sparks can also cause fires and
explosions. Therefore:
1. Remove all combustible materials well away from
the work area or cover the materials with a protective
non-flammable covering. Combustible materials
include wood, cloth, sawdust, liquid and gas fuels,
solvents, paints and coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks
or crevices in floors or wall openings and cause a
hidden smoldering fire or fires on the floor below.
Make certain that such openings are protected from
hot sparks and metal.“
3. Do not weld, cut or perform other hot work until
the workpiece has been completely cleaned so
that there are no substances on the workpiece
which MIGht produce flammable or toxic vapors.
Do not do hot work on closed containers. They may
explode.
4. Have fire extinguishing equipment handy for instant
use, such as a garden hose, water pail, sand bucket,
or portable fire extinguisher. Be sure you are trained
in its use.
5. Do not use equipment beyond its ratings. For
example, overloaded welding cable can overheat
and create a fire hazard.
6. After completing operations, inspect the work area
to make certain there are no hot sparks or hot metal
which could cause a later fire. Use fire watchers
when necessary.
7. For additional information, refer to NFPA Standard
51B, "Fire Prevention in Use of Cutting and Welding
Processes", available from the National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA
02269.
ELECTRICAL SHOCK -- Contact with
live electrical parts and ground can
cause severe injury or death. DO NOT
use AC welding current in damp areas,
if movement is confined, or if there is
danger of falling.
 safety precautions
1. Be sure the power source frame (chassis) is
connected to the ground system of the input
power.
2. Connect the workpiece to a good electrical
ground.
3. Connect the work cable to the workpiece. A poor
or missing connection can expose you or others
to a fatal shock.
4. Use well-maintained equipment. Replace worn
or damaged cables.
5. Keep everything dry, including clothing, work
area, cables, torch/electrode holder, and power
source.
6. Make sure that all parts of your body are insulated
from work and from ground.
7. Do not stand directly on metal or the earth while
working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear
rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the
power.
9. Turn off the power before removing your
gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specific grounding recommenda-
tions. Do not mistake the work lead for a ground
cable.
ELECTRIC AND MAGNETIC FIELDS
— May be dangerous. Electric cur-
rent flowing through any conduc-
tor causes localized Electric and Magnetic Fields
(EMF). Welding and cutting current creates EMF
around welding cables and welding machines.
Therefore:
1. Welders having pacemakers should consult their
physician before welding. EMF may interfere with
some pacemakers.
2. Exposure to EMF may have other health effects
which are unknown.
6
3. Welders should use the following procedures to
minimize exposure to EMF:
A. Route the electrode and work cables together.
Secure them with tape when possible.
B. Never coil the torch or work cable around your
body.
C. Do not place your body between the torch and
work cables. Route cables on the same side of
your body.
D. Connect the work cable to the workpiece as close
as possible to the area being welded.
E. Keep welding power source and cables as far
away from your body as possible.
FUMES AND GASES -- Fumes and
gases, can cause discomfort or
harm, particularly in confined
spaces. Do not breathe fumes and
gases. Shielding gases can cause
asphyxiation. Therefore:
1. Always provide adequate ventilation in the work
area by natural or mechanical means. Do not weld,
cut, or gouge on materials such as galvanized
steel, stainless steel, copper, zinc, lead, beryllium,
or cadmium unless positive mechanical ventila-
tion is provided. Do not breathe fumes from these
materials.
2. Do not operate near degreasing and spraying opera-
tions. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly
toxic gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat
irritation while operating, this is an indication
that ventilation is not adequate. Stop work and
take necessary steps to improve ventilation in the
work area. Do not continue to operate if physical
discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.
 safety precautions
5. WARNING: This product, when used for welding
or cutting, produces fumes or gases
which contain chemicals known to
the State of California to cause birth
defects and, in some cases, cancer.
(California Health & Safety Code
§25249.5 et seq.)
CYLINDER HANDLING -- Cylinders,
if mishandled, can rupture and vio-
lently release gas. Sudden rupture
of cylinder, valve, or relief device can
injure or kill. Therefore:
1. Use the proper gas for the process and use the
proper pressure reducing regulator designed to
operate from the compressed gas cylinder. Do not
use adaptors. Maintain hoses and fittings in good
condition. Follow manufacturer's operating instruc-
tions for mounting regulator to a compressed gas
cylinder.
2. Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercar-
riages, benches, walls, post, or racks. Never secure
cylinders to work tables or fixtures where they may
become part of an electrical circuit.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not con-
nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard
P-1, "Precautions for Safe Handling of Compressed
Gases in Cylinders", which is available from Com-
pressed Gas Association, 1235 Jefferson Davis
Highway, Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
7
1. Always have qualified personnel perform the instal-
lation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualified to perform such work.
2. Before performing any maintenance work inside a
power source, disconnect the power source from
the incoming electrical power.
3. Maintain cables, grounding wire, connections,
power cord, and power supply in safe working
order. Do not operate any equipment in faulty
condition.
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in posi-
tion and in good repair.
6. Use equipment only for its intended purpose. Do
not modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for
electric arc welding and cutting equipment,
ask your supplier for a copy of "Precautions
and Safe Practices for Arc Welding, Cutting
and Gouging", Form 52-529.
The following publications, which are available from
the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma
Arc Welding"
3. AWS C5.2 - "Recommended Practices for Plasma
Arc Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
 safety precautions

5. AWS C5.5 - "Recommended Practices for Gas Tung-

sten Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal

Arc Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Hand-

book.

8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have Held
Hazardous Substances."

Meaning of symbols - As used

throughout this manual: Means Atten-
tion! Be Alert! Your safety is involved.

Means immediate hazards which,

if not avoided, will result in im-
mediate, serious personal injury
or loss of life.

Means potential hazards which

could result in personal injury or
loss of life.

Means hazards which could result

in minor personal injury.

8
 sEGURIDAD
La escoria puede estar caliente y desprenderse con
1.2 Safety - Spanish velocidad. Personas cercanas deberán usar gafas
de seguridad y careta protectora.
ADVERTENCIA: Estas Precauciones de Se-
guridad son para su protección. Ellas hacen
FUEGO Y EXPLOSIONES -- El calor de
resumen de información proveniente de las
las flamas y el arco pueden ocacionar
referencias listadas en la sección "Información Adi-
fuegos. Escoria caliente y las chispas
cional Sobre La Seguridad". Antes de hacer cualquier
pueden causar fuegos y explosiones.
instalación o procedimiento de operación , asegúrese
Por lo tanto:
de leer y seguir las precauciones de seguridad listadas
a continuación así como también todo manual, hoja
1. Remueva todo material combustible lejos del área
de datos de seguridad del material, calcomanias, etc.
de trabajo o cubra los materiales con una cobija a
El no observar las Precauciones de Seguridad puede
prueba de fuego. Materiales combustibles incluyen
resultar en daño a la persona o muerte.
madera, ropa, líquidos y gases flamables, solventes,
pinturas, papel, etc.
PROTEJASE USTED Y A LOS DEMAS--
2. Chispas y partículas de metal pueden introducirse
Algunos procesos de soldadura, corte
en las grietas y agujeros de pisos y paredes cau-
y ranurado son ruidosos y requiren
sando fuegos escondidos en otros niveles o espa-
protección para los oídos. El arco,
cios. Asegúrese de que toda grieta y agujero esté
como el sol , emite rayos ultravioleta
cubierto para proteger lugares adyacentes contra
(UV) y otras radiaciones que pueden dañar la piel
fuegos.
y los ojos. El metal caliente causa quemaduras. EL
3. No corte, suelde o haga cualquier otro trabajo
entrenamiento en el uso propio de los equipos y
relacionado hasta que la pieza de trabajo esté to-
sus procesos es esencial para prevenir accidentes.
talmente limpia y libre de substancias que puedan
Por lo tanto:
producir gases inflamables o vapores tóxicos. No
trabaje dentro o fuera de contenedores o tanques
1. Utilice gafas de seguridad con protección a los lados
cerrados. Estos pueden explotar si contienen va-
siempre que esté en el área de trabajo, aún cuando
pores inflamables.
esté usando careta de soldar, protector para su cara
4. Tenga siempre a la mano equipo extintor de fu-
u otro tipo de protección.
ego para uso instantáneo, como por ejemplo una
2. Use una careta que tenga el filtro correcto y lente
manguera con agua, cubeta con agua, cubeta con
para proteger sus ojos, cara, cuello, y oídos de las
arena, o extintor portátil. Asegúrese que usted esta
chispas y rayos del arco cuando se esté operando y
entrenado para su uso.
observando las operaciones. Alerte a todas las per-
5. No use el equipo fuera de su rango de operación. Por
sonas cercanas de no mirar el arco y no exponerse
ejemplo, el calor causado por cable sobrecarga en
a los rayos del arco eléctrico o el metal fundido.
los cables de soldar pueden ocasionar un fuego.
3. Use guantes de cuero a prueba de fuego, camisa
6. Después de termirar la operación del equipo, inspec-
pesada de mangas largas, pantalón de ruedo liso,
cione el área de trabajo para cerciorarse de que las
zapato alto al tobillo, y careta de soldar con capucha
chispas o metal caliente ocasionen un fuego más
para el pelo, para proteger el cuerpo de los rayos y
tarde. Tenga personal asignado para vigilar si es
chispas calientes provenientes del metal fundido.
necesario.
En ocaciones un delantal a prueba de fuego es
7. Para información adicional , haga referencia a la
necesario para protegerse del calor radiado y las
publicación NFPA Standard 51B, "Fire Prevention in
chispas.
Use of Cutting and Welding Processes", disponible
4. Chispas y partículas de metal caliente puede alojarse
a través de la National Fire Protection Association,
en las mangas enrolladas de la camisa , el ruedo del
Batterymarch Park, Quincy, MA 02269.
pantalón o los bolsillos. Mangas y cuellos deberán
mantenerse abotonados, bolsillos al frente de la
CHOQUE ELECTRICO -- El contacto
camisa deberán ser cerrados o eliminados.
con las partes eléctricas energizadas
5. Proteja a otras personas de los rayos del arco y
y tierra puede causar daño severo o
chispas calientes con una cortina adecuada no-
muerte. NO use soldadura de corriente
flamable como división.
alterna (AC) en áreas húmedas, de
6. Use careta protectora además de sus gafas de seguri-
movimiento confinado en lugares estrechos o si
dad cuando esté removiendo escoria o puliendo.
hay posibilidad de caer al suelo.
9
 sEGURIDAD
1. Asegúrese de que el chasis de la fuente de poder
esté conectado a tierra através del sistema de
electricidad primario.
2. Conecte la pieza de trabajo a un buen sistema
de tierra física.
3. Conecte el cable de retorno a la pieza de trabajo.
Cables y conductores expuestos o con malas
conexiones pueden exponer al operador u otras
personas a un choque eléctrico fatal.
4. Use el equipo solamente si está en buenas condi-
ciones. Reemplaze cables rotos, dañados o con
conductores expuestos.
5. Mantenga todo seco, incluyendo su ropa, el
área de trabajo, los cables, antorchas, pinza del
electrodo, y la fuente de poder.
6. Asegúrese que todas las partes de su cuerpo están
insuladas de ambos, la pieza de trabajo y tierra.
7. No se pare directamente sobre metal o tierra
mientras trabaja en lugares estrechos o áreas
húmedas; trabaje sobre un pedazo de madera
seco o una plataforma insulada y use zapatos
con suela de goma.
8. Use guantes secos y sin agujeros antes de ener-
gizar el equipo.
9. Apage el equipo antes de quitarse sus guantes.
10. Use como referencia la publicación ANSI/ASC
Standard Z49.1 (listado en la próxima página) para
recomendaciones específicas de como conectar
el equipo a tierra. No confunda el cable de soldar
a la pieza de trabajo con el cable a tierra.
CAMPOS ELECTRICOS Y MAG-
NETICOS - Son peligrosos. La
corriente eléctrica fluye através
de cualquier conductor causando
a nivel local Campos Eléctricos y
Magnéticos (EMF). Las corrientes en el área de
corte y soldadura, crean EMF alrrededor de los
cables de soldar y las maquinas. Por lo tanto:
1. Soldadores u Operadores que use marca-pasos para
el corazón deberán consultar a su médico antes de
soldar. El Campo Electromagnético (EMF) puede
interferir con algunos marca-pasos.
2. Exponerse a campos electromagnéticos (EMF)
puede causar otros efectos de salud aún descono-
cidos.
10
3. Los soldadores deberán usar los siguientes proced-
imientos para minimizar exponerse al EMF:
A. Mantenga el electrodo y el cable a la pieza de
trabajo juntos, hasta llegar a la pieza que usted
quiere soldar. Asegúrelos uno junto al otro con
cinta adhesiva cuando sea posible.
B. Nunca envuelva los cables de soldar alrededor
de su cuerpo.
C. Nunca ubique su cuerpo entre la antorcha y el
cable, a la pieza de trabajo. Mantega los cables
a un sólo lado de su cuerpo.
D. Conecte el cable de trabajo a la pieza de trabajo
lo más cercano posible al área de la soldadu-
ra.
E. Mantenga la fuente de poder y los cables de
soldar lo más lejos posible de su cuerpo.
HUMO Y GASES -- El humo y los
gases, pueden causar malestar o
daño, particularmente en espacios
sin ventilación. No inhale el humo
o gases. El gas de protección puede causar falta
de oxígeno. Por lo
tanto:
1. Siempre provea ventilación adecuada en el
área de trabajo por medio natural o mecánico.
No solde, corte, o ranure materiales con hierro
galvanizado, acero inoxidable, cobre, zinc, plomo,
berílio, o cadmio a menos que provea venti-
lación mecánica positiva . No respire los gases
producidos por estos materiales.
2. No opere cerca de lugares donde se aplique sub-
stancias químicas en aerosol. El calor de los rayos
del arco pueden reaccionar con los vapores de
hidrocarburo clorinado para formar un fosfógeno,
o gas tóxico, y otros irritant es.
3. Si momentáneamente desarrolla inrritación de
ojos, nariz o garganta mientras est á operando,
es indicación de que la ventilación no es apro-
piada. Pare de trabajar y tome las medidas
necesarias para mejorar la ventilación en el
área de trabajo. No continúe operando si el
malestar físico persiste.
4. Haga referencia a la publicación ANSI/ASC Stan-
dard Z49.1 (Vea la lista a continuación) para
recomendaciones específicas en la ventilación.
 sEGURIDAD
5. ADVERTENCIA-- Este producto cuando se uti-
liza para soldaduras o cortes,
produce humos o gases, los
cuales contienen químicos menos que usted esté cualificado para hacer el
conocidos por el Estado de
California de causar defectos
en el nacimiento, o en algu-
nos casos, Cancer. (California
Health & Safety Code §25249.5
et seq.)
MANEJO DE CILINDROS-- Los
cilindros, si no son manejados
correctamente, pueden romp-
erse y liberar violentamente
gases. Rotura repentina del
cilindro, válvula, o válvula de
escape puede causar daño o
muerte. Por lo tanto:
1. Utilize el gas apropiado para el proceso y utilize
un regulador diseñado para operar y reducir la
presión del cilindro de gas . No utilice adapta-
dores. Mantenga las mangueras y las conexiones
en buenas condiciones. Observe las instrucciones
de operación del manufacturero para montar el
regulador en el cilindro de gas comprimido.
2. Asegure siempre los cilindros en posición vertical
y amárrelos con una correa o cadena adecuada
para asegurar el cilindro al carro, transportes, tablil-
leros, paredes, postes, o armazón. Nunca asegure
los cilindros a la mesa de trabajo o las piezas que
son parte del circuito de soldadura . Este puede
ser parte del circuito elélectrico.
3. Cuando el cilindro no está en uso, mantenga la
válvula del cilindro cerrada. Ponga el capote de
protección sobre la válvula si el regulador no
está conectado. Asegure y mueva los cilindros
utilizando un carro o transporte adecuado. Evite
el manejo brusco de los
MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede
causar daño o muerte. Por lo tanto:
11
1. Siempre tenga personal cualificado para efec-
tuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
trabajo.
2. Antes de dar mantenimiento en el interior de la
fuente de poder, desconecte la fuente de poder
del suministro de electricidad primaria.
3. Mantenga los cables, cable a tierra, conexciones,
cable primario, y cualquier otra fuente de poder
en buen estado operacional. No opere ningún
equipo en malas condiciones.
4. No abuse del equipo y sus accesorios. Mantenga
el equipo lejos de cosas que generen calor como
hornos, también lugares húmedos como charcos
de agua , aceite o grasa, atmósferas corrosivas y
las inclemencias del tiempo.
5. Mantenga todos los artículos de seguridad y
coverturas del equipo en su posición y en buenas
condiciones.
6. Use el equipo sólo para el propósito que fue
diseñado. No modifique el equipo en ninguna
manera.
INFORMACION ADICIONAL DE SEGURI-
DAD -- Para más información sobre las
prácticas de seguridad de los equipos
de arco eléctrico para soldar y cortar,
pregunte a su suplidor por una copia
de "Precautions and Safe Practices for
Arc Welding, Cutting and Gouging-Form
52-529.
Las siguientes publicaciones, disponibles através de
la American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, son recomendadas para usted:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma
Arc Welding"
3. AWS C5.2 - "Recommended Practices for Plasma
Arc Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
 sEGURIDAD

SIGNIFICADO DE LOS sImbolOs

-- Según usted avanza en la lectura
de este folleto: Los Símbolos Sig-
nifican ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.

Significa riesgo inmediato que,

de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.

Significa el riesgo de un peligro

potencial que puede resultar en
serio daño personal o la muerte.

Significa el posible riesgo que

puede resultar en menores daños
a la persona.

12
 sÉCURITÉ
1.3 Safety - French
AVERTISSEMENT : Ces règles de sécurité
ont pour but d'assurer votre protection. Ils
récapitulent les informations de précaution
provenant des références dans la section des
Informations de sécurité supplémentaires.
Avant de procéder à l'installation ou d'utiliser l'unité,
assurez-vous de lire et de suivre les précautions de sécu-
rité ci-dessous, dans les manuels, les fiches d'information
sur la sécurité du matériel et sur les étiquettes, etc. Tout
défaut d'observer ces précautions de sécurité peut
entraîner des blessures graves ou mortelles.
PROTÉGEZ-VOUS -- Les processus de
soudage, de coupage et de gougeage
produisent un niveau de bruit élevé et
exige l'emploi d'une protection audi-
tive. L'arc, tout comme le soleil, émet des rayons
ultraviolets en plus d'autre rayons qui peuvent
causer des blessures à la peau et les yeux. Le mé-
tal incandescent peut causer des brûlures. Une
formation reliée à l'usage des processus et de
l'équipement est essentielle pour prévenir les ac-
cidents. Par conséquent:
1. Portez des lunettes protectrices munies d'écrans la-
téraux lorsque vous êtes dans l'aire de travail, même
si vous devez porter un casque de soudeur, un écran
facial ou des lunettes étanches.
2. Portez un écran facial muni de verres filtrants et de
plaques protectrices appropriées afin de protéger
vos yeux, votre visage, votre cou et vos oreilles des
étincelles et des rayons de l'arc lors d'une opération
ou lorsque vous observez une opération. Avertis-
sez les personnes se trouvant à proximité de ne pas
regarder l'arc et de ne pas s'exposer aux rayons de
l'arc électrique ou le métal incandescent.
3. Portez des gants ignifugiés à crispin, une chemise
épaisse à manches longues, des pantalons sans
rebord et des chaussures montantes afin de vous
protéger des rayons de l'arc, des étincelles et du métal
incandescent, en plus d'un casque de soudeur ou cas-
quette pour protéger vos cheveux. Il est également
recommandé de porter un tablier ininflammable afin
de vous protéger des étincelles et de la chaleur par
rayonnement.
4. Les étincelles et les projections de métal incandescent
risquent de se loger dans les manches retroussées,
les rebords de pantalons ou les poches. Il est recom-
mandé de garder boutonnés le col et les manches
et de porter des vêtements sans poches en avant.
5. Protégez toute personne se trouvant à proximité des
étincelles et des rayons de l'arc à l'aide d'un rideau
ou d'une cloison ininflammable.
6. Portez des lunettes étanches par dessus vos lunettes
de sécurité lors des opérations d'écaillage ou de
meulage du laitier. Les écailles de laitier incandescent
peuvent être projetées à des distances considérables.
Les personnes se trouvant à proximité doivent égale-
ment porter des lunettes étanches par dessus leur
lunettes de sécurité.
13
INCENDIES ET EXPLOSIONS -- La
chaleur provenant des flammes ou de
l'arc peut provoquer un incendie. Le
laitier incandescent ou les étincelles
peuvent également provoquer un
incendie ou une explosion. Par conséquent :
1. Éloignez suffisamment tous les matériaux combus-
tibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininflammable. Les
matériaux combustibles incluent le bois, les vête-
ments, la sciure, le gaz et les liquides combustibles,
les solvants, les peintures et les revêtements, le
papier, etc.
2. Les étincelles et les projections de métal incan-
descent peuvent tomber dans les fissures dans
les planchers ou dans les ouvertures des murs et
déclencher un incendie couvant à l'étage inférieur
Assurez-vous que ces ouvertures sont bien proté-
gées des étincelles et du métal incandescent.
3. N'exécutez pas de soudure, de coupe ou autre tra-
vail à chaud avant d'avoir complètement nettoyé la
surface de la pièce à traiter de façon à ce qu'il n'ait
aucune substance présente qui pourrait produire
des vapeurs inflammables ou toxiques. N'exécutez
pas de travail à chaud sur des contenants fermés
car ces derniers pourraient exploser.
4. Assurez-vous qu'un équipement d'extinction
d'incendie est disponible et prêt à servir, tel qu'un
tuyau d'arrosage, un seau d'eau, un seau de sable
ou un extincteur portatif. Assurez-vous d'être bien
instruit par rapport à l'usage de cet équipement.
5. Assurez-vous de ne pas excéder la capacité de
l'équipement. Par exemple, un câble de soudage
surchargé peut surchauffer et provoquer un in-
cendie.
6. Une fois les opérations terminées, inspectez l'aire
de travail pour assurer qu'aucune étincelle ou
projection de métal incandescent ne risque de
provoquer un incendie ultérieurement. Employez
des guetteurs d'incendie au besoin.
7. Pour obtenir des informations supplémentaires,
consultez le NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible
au National Fire Protection Association, Battery-
march Park, Quincy, MA 02269.
CHOC ÉLECTRIQUE -- Le contact avec
des pièces électriques ou les pièces de
mise à la terre sous tension peut causer
des blessures graves ou mortelles. NE
PAS utiliser un courant de soudage c.a.
dans un endroit humide, en espace restreint ou si
un danger de chute se pose.
 sÉCURITÉ
1. Assurez-vous que le châssis de la source
d'alimentation est branché au système de mise à
la terre de l'alimentation d'entrée.
2. Branchez la pièce à traiter à une bonne mise de
terre électrique.
3. Branchez le câble de masse à la pièce à traiter
et assurez une bonne connexion afin d'éviter le
risque de choc électrique mortel.
4. Utilisez toujours un équipement correctement
entretenu. Remplacez les câbles usés ou endom-
magés. côté de votre corps.
5. Veillez à garder votre environnement sec, incluant
les vêtements, l'aire de travail, les câbles, le porte-
électrode/torche et la source d'alimentation.
6. Assurez-vous que tout votre corps est bien isolé
de la pièce à traiter et des pièces de la mise à la
terre.
7. Si vous devez effectuer votre travail dans un
espace restreint ou humide, ne tenez vous pas
directement sur le métal ou sur la terre; tenez-
vous sur des planches sèches ou une plate-forme
isolée et portez des chaussures à semelles de
caoutchouc.
8. Avant de mettre l'équipement sous tension, isolez
vos mains avec des gants secs et sans trous.
9. Mettez l'équipement hors tension avant d'enlever
vos gants.
10. Consultez ANSI/ASC Standard Z49.1 (listé à
la page suivante) pour des recommandations
spécifiques concernant les procédures de mise à
la terre. Ne pas confondre le câble de masse avec
le câble de mise à la terre.
CHAMPS ÉLECTRIQUES ET MAGNÉ-
TIQUES — comportent un risque
de danger. Le courant électrique
qui passe dans n'importe quel
conducteur produit des champs
électriques et magnétiques localisés. Le soud-
age et le courant de coupage créent des champs
électriques et magnétiques autour des câbles de
soudage et l'équipement. Par conséquent :
1. Un soudeur ayant un stimulateur cardiaque doit
consulter son médecin avant d'entreprendre une
opération de soudage. Les champs électriques
et magnétiques peuvent causer des ennuis pour
certains stimulateurs cardiaques.
2. L'exposition à des champs électriques et magné-
tiques peut avoir des effets néfastes inconnus pour
la santé.
14
3. Les soudeurs doivent suivre les procédures suiv-
antes pour minimiser l'exposition aux champs
électriques et magnétiques :
A. Acheminez l'électrode et les câbles de masse
ensemble. Fixez-les à l'aide d'une bande adhésive
lorsque possible.
B. Ne jamais enrouler la torche ou le câble de masse
autour de votre corps.
C. Ne jamais vous placer entre la torche et les câbles
de masse. Acheminez tous les câbles sur le même
D. Branchez le câble de masse à la pièce à traiter le
plus près possible de la section à souder.
E. Veillez à garder la source d'alimentation pour le
soudage et les câbles à une distance appropriée
de votre corps.
LES VAPEURS ET LES GAZ -- peuvent
causer un malaise ou des dommag-
es corporels, plus particulièrement
dans les espaces restreints. Ne re-
spirez pas les vapeurs et les gaz. Le
gaz de protection risque de causer
l'asphyxie. Par conséquent :
1. Assurez en permanence une ventilation adéquate
dans l'aire de travail en maintenant une ventila-
tion naturelle ou à l'aide de moyens mécanique.
N'effectuez jamais de travaux de soudage, de
coupage ou de gougeage sur des matériaux tels que
l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc,
le plomb, le berylliym ou le cadmium en l'absence
de moyens mécaniques de ventilation efficaces. Ne
respirez pas les vapeurs de ces matériaux.
2. N'effectuez jamais de travaux à proximité d'une
opération de dégraissage ou de pulvérisation.
Lorsque la chaleur
ou le rayonnement de l'arc entre en contact avec
les vapeurs d'hydrocarbure chloré, ceci peut
déclencher la formation de phosgène ou d'autres
gaz irritants, tous extrêmement toxiques.
3. Une irritation momentanée des yeux, du nez ou
de la gorge au cours d'une opération indique que
la ventilation n'est pas adéquate. Cessez votre tra-
vail afin de prendre les mesures nécessaires pour
améliorer la ventilation dans l'aire de travail. Ne
poursuivez pas l'opération si le malaise persiste.
4. Consultez ANSI/ASC Standard Z49.1 (à la page
suivante) pour des recommandations spécifiques
concernant la ventilation.
 sÉCURITÉ

ENTRETIEN DE L'ÉQUIPEMENT -- Un
5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé
équipement entretenu de façon défec-
dans une opération de soudage ou de
tueuse ou inadéquate peut causer
coupage, dégage des vapeurs ou des
des blessures graves ou mortelles. Par
gaz contenant des chimiques consid-
conséquent :
éres par l'état de la Californie comme
1. Efforcez-vous de toujours confier les tâches
étant une cause des malformations
d'installation, de dépannage et d'entretien à un
congénitales et dans certains cas, du
personnel qualifié. N'effectuez aucune réparation
cancer. (California Health & Safety
électrique à moins d'être qualifié à cet effet.
Code §25249.5 et seq.)
2. Avant de procéder à une tâche d'entretien à
l'intérieur de la source d'alimentation, débranchez
MANIPULATION DES CYLINDRES --
l'alimentation électrique.
La manipulation d'un cylindre, sans
3. Maintenez les câbles, les fils de mise à la terre,
observer les précautions nécessaires,
les branchements, le cordon d'alimentation et la
peut produire des fissures et un
source d'alimentation en bon état. N'utilisez jamais
échappement dangereux des gaz. Une
un équipement s'il présente une défectuosité
brisure soudaine du cylindre, de la soupape ou du
quelconque.
dispositif de surpression peut causer des blessures
4. N'utilisez pas l'équipement de façon abusive. Gardez
graves ou mortelles. Par conséquent :
l'équipement à l'écart de toute source de chaleur,
notamment des fours, de l'humidité, des flaques
1. Utilisez toujours le gaz prévu pour une opération
d'eau, de l'huile ou de la graisse, des atmosphères
et le détendeur approprié conçu pour utilisation
corrosives et des intempéries.
sur les cylindres de gaz comprimé. N'utilisez jamais
5. Laissez en place tous les dispositifs de sécurité et
d'adaptateur. Maintenez en bon état les tuyaux et
tous les panneaux de la console et maintenez-les
les raccords. Observez les instructions d'opération
en bon état.
du fabricant pour assembler le détendeur sur un
6. Utilisez l'équipement conformément à son usage
cylindre de gaz comprimé.
prévu et n'effectuez aucune modification.
2. Fixez les cylindres dans une position verticale, à
l'aide d'une chaîne ou une sangle, sur un chariot
manuel, un châssis de roulement, un banc, un mur,
INFORMATIONS SUPPLÉMENTAIRES
une colonne ou un support convenable. Ne fixez
RELATIVES À LA SÉCURITÉ -- Pour obte-
jamais un cylindre à un poste de travail ou toute au-
nir de l'information supplémentaire sur
tre dispositif faisant partie d'un circuit électrique.
les règles de sécurité à observer pour
3. Lorsque les cylindres ne servent pas, gardez les
l'équipement de soudage à l'arc électrique
soupapes fermées. Si le détendeur n'est pas bran-
et le coupage, demandez un exemplaire
ché, assurez-vous que le bouchon de protection de
du livret "Precautions and Safe Practices
la soupape est bien en place. Fixez et déplacez les
for Arc Welding, Cutting and Gouging",
cylindres à l'aide d'un chariot manuel approprié.
Form 52-529.
Toujours manipuler les cylindres avec soin.
4. Placez les cylindres à une distance appropriée
de toute source de chaleur, des étincelles et des
Les publications suivantes sont également recom-
flammes. Ne jamais amorcer l'arc sur un cylindre.
mandées et mises à votre disposition par l'American
5. Pour de l'information supplémentaire, consultez
Welding Society, 550 N.W. LeJuene Road, Miami, FL
CGA Standard P-1, "Precautions for Safe Handling
33126 :
of Compressed Gases in Cylinders", mis à votre dis-
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
position par le Compressed Gas Association, 1235
2. AWS C5.1 - "Recommended Practices for Plasma
Jefferson Davis Highway, Arlington, VA 22202.
Arc Welding"
3. AWS C5.2 - "Recommended Practices for Plasma
Arc Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"

15
 sÉCURITÉ

SIGNIFICATION DES SYMBOLES

Ce symbole, utilisé partout dans ce man-
uel, signifie "Attention" ! Soyez vigilant !
Votre sécurité est en jeu.

DANGER
Signifie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.

AVERTISSEMENT
Signifie un danger potentiel qui peut entraîner
des blessures graves ou mortelles.

ATTENTION
Signifie un danger qui peut entraîner des blessures
corporelles mineures.

16
SECTION 1 DESCRIPTION

1.0 SAFETY REFERENCES

Before the DuraDrive 4-30 wire feeder is put into operation, the safety section at the front of this manual should be read
completely. This will help avoid possible injury due to misuse or improper installation.

1.1 DESCRIPTION AND SPECIFICATIONS

The DuraDrive 4-30 is a 4 roll drive 42 vac wire feeder with the ability to meet immediate and long term welding requirements
of any weld shop. It's "Modular Design" technology permits simplicity and flexibility without unnecessary configuration
and installation complexity. The DuraDrive control panels (MMI or Man/Machine Interface) can be easily replaced (plug and
play) with optional panels having more functionality and features.

The DuraDrive 4-30 wire feeder will handle most welding applications using short arc, spray and pulsed spray arc MIG (GMAW,
GMAW-P & MCAW) welding or cored wire (FCAW ) welding with a variety of welding power sources.

A. FEATURES:
• Modular MMI (Man/Machine Interface) panels for easy function and feature upgradability
• Heavy duty compact wire feed motor
• Quick release 4-roll drive assembly; no readjustment of pressure required when rethreading wire.
• Quick release “No Tools” feed roll system
• Driven upper and lower drive rolls for positive feed force and maximum wire grip.
• All control circuits incorporated on one solid‑state printed circuit board, mounted for easy access and removal.
• Gas purge switch for shield gas flowrate preset.
• Slow run-in switch sets the wire feed speed at 1/2 the preset until the arc is struck for smoother arc starting.
• Jog switch for wire inching without energizing power source contactor.
• Anti‑stick wire burnback control for precise adjustment of amount of wire burnback after wire feed stops, to eliminate
freezing of wire in weld pool.
• Low voltage circuit (12v) for gun trigger switch, to assure operator safety.
• NAS (#4 Tweco) gun adapter
• All cable and hose connections are quickly detachable.

B. SPECIFICATIONS

Input Power Required . .............................................................42 volts, 60 hz, Single Phase

Wire Feed Range:

Low Range - 50 to 700 in/min (1.2‑18 m/min)
High Range - 350 to 999 in/min (9-25 m/min)

Wire Sizes :
Hard (V-Groove). . . . .............................................................. . 023 thru 1/16‑in.(.6 - 1.6 mm)
Tubular (Knurled)....................................................................... 035 thru 5/64‑in.(.9 - 2.0mm)
Soft (U-Groove). . . .................................................................. .030 thru 1/16‑in.(.8 - 1.6 mm)

Dimensions:
Length .................................................................................................................22.5‑in. (572 mm)
Width ...................................................................................................................10.5‑in. (268 mm)
Height . .................................................................................................................16.5‑in (419 mm)
Weight (less wire & cables) ................................................................................46‑lbs. (21 kg).

17
SECTION 1 DESCRIPTION

C. Modular MMI (Man/Machine Interface) Panel System

Introduction
The interchangeable control panels (MMI) are available in 4 different models depending on the needs of the welding opera-
tor and the welding application. The panels are designed for easily removal and replacement. The following describes the
functions and capability of each MMI panel.

Basic MMI Panel

The Basic MMI panel is the simplest design with one CV welding schedule having a wire feed speed adjustment and remote
voltage adjustment (if the power source is capable of remote voltage control).

Basic Dual Schedule MMI Panel

The Basic Dual Schedule MMI panel allows the preset of two sets of welding parameters. Both wire feed speed IPM or
VOLTS can be preset on power sources with remote voltage capability. The SCHEDULE select switch determines the weld-
ing schedule (A or B) to be used when the gun trigger is depressed. The welding schedules (parameters) can be switched
while welding using the "Click Click" trigger technique where the gun trigger is released and depressed quickly (within 0.2
sec). This option module can be used to provide a hot start, crater fill or a gap filling welding parameter in addition to the
standard welding parameter typically used for the given weld application.

NOTE
For ALL dual schedule MMI panels, a weld schedule can be disabled by placing the wire feed speed
knob to the minimum position or "0" (zero) position. This will eliminate the accidental triggering of the
Mig gun into the alternate weld schedule.

18
SECTION 1 DESCRIPTION

NOTE
Either the 4-in-1 Option Module or the Pulse Selection Option Module can be installed NOT BOTH

Digital Dual Schedule MMI Panel

The Digital Dual Schedule MMI panel has all the capability of the Basic Dual Schedule panel with the addition of a digital
WFS and VOLT meter. The digital WFS meters adds digital presettability to the wire feed speed. The digital wire feed speed
can be preset to the IPM (inches per minute) setting desired and the control circuitry will maintain that wire feed speed
within +/- 2 ipm. A preset display of the arc voltage is NOT supported. During welding, the average WFS and VOLTS is
calculated and the display updated 3 times a second. The last reading is then held for 10 seconds after welding has com-
pleted for weld parameter verification and recording.

Digital Dual Schedule Pulse MMI Panel

The Digital Dual Schedule Pulse MMI panel adds Pulse MIG welding capability and is the most advanced MMI panel for the
DuraDrive feeder line. Two welding parameters can be preset on the panel in either the standard (CV) or pulse MIG process
mode. The arc starting schedule is selected with the SCHEDULE select switch (A or B). The "Click Click" gun trigger schedule
switching technique can be used to change welding parameters while welding. This MMI panel MUST be used with a PULSE
SELECTION module installed on the wire feeder control cabinet rear panel. This module can be used with the ESAB 350MPi,
MTS-3500i, SVI-450i and MultiPower 460 (non-pulse version) power sources for MIG pulse welding. The DuraDrive feeder
is factory shipped configured for the ESAB 350MPi, MTS-3500i and MultiPower 460 power sources. MMI installation and
setup instructions for the SVI-450i power source configuration are included in the Dual Pulse MMI installation instructions
F15-703. Other ESAB power sources and competitors power sources will not operate in the pulse mode using this Pulse
MMI panel.
NOTE
Power sources with pulsing capability built into the power source (such as the MultiPower 460 Pulse)
can utilize any of the MMI panels for pulse operation and does NOT require the Digital Dual; Schedule
Pulse MMI panel.

19
SECTION 1 DESCRIPTION

NOTE
A continuous water supply or re-circulator is required when using a water cooled MIG gun.

D. Front Panel Components

1. Modular MMI panel
2. Power On/Off Switch
Controls the 42 vac power from the power source.
3. Wire Jog Switch
Used to safely thread the wire through the gun liner without applying welding power to the wire or gun assem-
bly.
4. Gas Purge Switch
Used to preset the shield gas flowrate without applying welding power to the wire or gun assembly.
5. Gun Trigger Switch Receptacle
A two prong “twist to lock” receptacle used to connect the MIG gun trigger circuit to the wire feeder.
6. NAS (#4 Tweco) Power Pin MIG gun connection

E. Rear Panel:
1. Burnback (AntiStick) Adjustment
The control knob adjusts the time between the wire feed motor brake is applied and the welding contactor is
turned “off”. This determines how far the wire will burnback towards the contact tip after welding is completed. If
the wire is sticking in the weld pool, turn the knob clockwise a small amount and retest. Continue this procedure
until the wire cleans the top of the weld pool or burns back the desired amount.
2. Slow Run-in On/Off
When this switch is in the “On” position the wire speed will feed at 1/2 the preset wire feed speed until the arc is
struck. The arc detect circuit will then automatically switch to the preset wire feed speed.
3. Option Module Panel
Permits the mounting of an optional control modules that add functionality to the DuraDrive wire feeder.
4. Control Cable Receptacle
Receptacle that accepts the 19 pin control interconnect cable between the wire feeder and power source.
5. Shield Gas Connection
Connect the shielding gas hose from the regulator/flowmeter to this fitting.
6. Circuit Breaker
Prevents damage to the Main control PC board caused by excessive line current.
7. Power Connection Block
Insulated connection point for the welding cables from the secondary side of the welding power source.

I.2 RECOMMENDED OPTIONAL EQUIPMENT AND ACCESSORIES

A. Recommended Power Sources:

See Table 1 for the compatibility of power sources and applicable MMI panels. The following power sources are sup-
ported.
ESAB 350MPi
ESAB MTS-3500i
ESAB SVI‑450i
ESAB 353cv
ESAB 453cv
ESAB 653cvcc
ESAB MultiPower 460
ESAB MultiPower 460 Pulse.

20
SECTION 1 DESCRIPTION

WIRE FEED MODULAR MMI

SPEED AND (MAN/MACHINE INTERFACE)
VOLTAGE* PANEL

MIG
TORCH POWER "ON/OFF"
CONNECTOR SWITCH
RECEPTACLE

WIRE JOG
MIG AND
TORCH GAS PURGE
TRIGGER
RECEPTACLE

FRONT VIEW

SPOOL/REEL
5 A CIRCUIT SPINDLE
GAS POST
BREAKER
CONNECTION WIRE SPOOL HUB

OPTION
MODULE
PANEL

BURNBACK
ADJUSTMENT

WATER IN (WATER KIT IN-

STALLED)

SLOW RUN-IN
SWITCH

CONTROL CABLE WELDING POWER

RECEPTACLE INPUT BLOCK
REAR VIEW

Figure 1-1. DuraDrive4 - 30 Wire Feeder

21
SECTION 1 DESCRIPTION

B. Control Cable Assembly:

For connection of the DuraDrive 4-30 to ESAB power sources with a 19‑pin re­ceptacle, the following control cable as-
semblies are available:
8-foot (2.5m) - PN 0558002358
30‑foot (9. 0m), PN 30780
60‑foot (18m), PN 30781

Table 1-1 - MMI PANELS and POWER SOURCE COMPATIBILITY

MMI - Man / Machine Interface

Recommended Power Source Basic Basic Dual Digital Dual Pulse Dual
ESAB 353cv X X X
ESAB 453cv X X X
ESAB 653cvcc X X X
ESAB MultiPower 460 X X X X
ESAB MultiPower 460 Pulse X X X
ESAB 350MPi, MTS-3500i X X X X
ESAB SVI-450i X X X X

C. MIG Welding Guns:

Gun Master 250 Gas Cooled
Gun Master 400 Gas Cooled

D. MIG Gun Adapters (NAS - North American Standard)
Only Tweco #4 is supported

E. Feed Rolls and Outlet Guides:
The appropriate feed roll, outlet guide and center guide is required for optimum wire feeding. See Table 2-1.

F. Shielding Gas Regulator/Flowmeter:

R-33 FM 580 (Argon) - PN 21557
R-33 FM 360 (CO2) - PN 21558
R‑5007 Argon/Helium/Nitrogen - P/N 998124
R‑5008 CO2 - PN 998125.

G. Gas Hoses:
Argon/Helium, Nitrogen - P/N 40V77 (12‑1/2‑ft.) or PN 34V38 (25‑ft.)
Heavy Duty - PN 19416 (12‑1/2‑ft.)* or PN 19415 (25­ft.)*
* - Must be used for CO2 and can also be used for Argon/Helium/Nitrogen.

H. OPTIONAL ACCESSORIES

1. Basic Dual Schedule MMI Panel (PN 0558001913)

Used to add a second set of welding parameters for more flexibility and convenience. Easy to install kit includes
controls for setting a second set of welding conditions (wire feed speed and voltage). The welder can select Sched-
ule A or Schedule B on a switch located on the MMI panel.

22
SECTION 1 DESCRIPTION

2. Digital Dual Schedule MMI Panel (PN 0558001912)

This easy to install MMI panel provides digital meters to preset wire feed speed and display both wire feed speed
and average arc voltage while welding. Both wire feed speed (IPM) and arc voltage are displayed for 10 seconds
after the weld is completed for easy viewing and recording of weld parameters. Two welding schedules can be
preset and switched during welding by using the MIG gun trigger.
3. Pulse Dual Schedule MMI Kit (PN 0558002496)
This kit includes the Pulse Dual Schedule Panel (PN-0558003005) and the Pulse Selection Module (PN-0558003007)
and provides pulse MIG welding capability using the ESAB 350MPi, MTS-3500i, MultiPower 460 or SVI-450i power
sources.
4. 4-in-1 Pre/Post Flow, Spot Weld and Trigger Lock
(PN 0558001914)
This control module provides additional weld functions to the DuraDrive wire feeder.
a. Preflow/Postflow - The PREFLOW control sets the time of the preflow shielding gas before the wire starts feed-
ing (0-2.5 sec.). The POSTFLOW control sets the time the shielding gas remains “ON” after the arc is turned
“OFF” (0-2.5 sec.).

NOTE
Weld schedule selection using the MIG gun trigger is disabled when the 4-in-1 Option panel is installed
and the the TRIGGER LATCH function is being used.

b. Spot Weld Time - This knob sets the spot weld time from 0 to 10 seconds and is controlled by a current detect
switch. The timer does not start until current is detected to insure consistent weld results.
c. Spot Weld Switch Position - With the toggle switch in the SPOT (left) position the SPOT timer is turned “ON”
and the spot weld time is controlled by the SPOT WELD TIMER knob.
d. Continuous Position - With the toggle switch in the CONTINUOUS (center) position the welding continues as
long as the MIG gun trigger is depressed.
e. Trigger Lock Position - With the toggle switch in the TRIGGER LOCK (right) position, the welding process begins
when the gun trigger is depressed. Once the welding has started, the gun trigger may be released without
the arc going out. To stop the welding operation, the gun trigger must be depressed a second time or by
pulling the gun away and breaking the arc. This allows a continuous weld without having to continuously
depress the gun trigger

23
SECTION 1 DESCRIPTION

NOTE
If the Trigger Lock option has been installed and set to the "ON" position, the trigger switch lever can be
released when the arc has been struck. Depress the trigger lever a second time to stop the arc. If the gun
is withdrawn from the workpiece during welding, the arc will be interrupted and wire feeding will stop
automatically.

NOTE
A continuous water supply or re-circulator is required when using a water cooled MIG gun.

5. Lifting Bracket - Hanging Bail (PN 0558003047):

Mounts at the top of the wire feeder spool support. Enables you to mount the wire feeder overhead on a boom or
trolley system.
6. Spool Enclosure Kit (PN 0558002357):
Hinged cover and enclosure provides protection for spool of wire against dust and dirt.
7. Reel Assembly (PN 995570):
Reel slips over spindle to allow use of coiled wire.
8. Swivel Post (PN 36172):
Installs on power sources such as ESAB 353cv, 453cv MultiPower 460 and 460 Pulse, or 653cvcc and allows the wire
feeder to swivel freely.
9. Swivel Post w/Mounting Bracket (PN 34075):
Attaches to inverter cart (P/N 31700) or other flat mounting surface and allows the feeder to swivel freely
10. Handle Kit (PN 0558002356)
Includes handle with rubber grip and mounting hardware.
11. Wheel Kit (PN 34324))
Makes it easy to roll wire feeder around job site Cart includes base, front swivel caster wheels, rear caster wheels
and mounting hardware.
12. Counterbalance Mini-Boom (PN 0458705881)
Mounts to the power source swivel post and reduces wire feeding problems caused by sharp bends in the gun
liner and cables by keeping the gun cable off the floor. Includes boom and mounting hardware. (requires Swivel
Post - P/N 36172)
13. Marathon Pack Inlet Guide (PN 0558002354)
Allows the secure connection of a Marathon Pack conduit/liner to the rear panel of the DuraDrive wire feeder.

Requires:
Quick Disconnect Adaptor Kit (QAC)..................................... P/N 899F50

NOTE
The DuraDrive feeder is not compatible and cannot be used with the UltraPulse 450i Pendant.

24
SECTION 2 INSTALLATION

2.0 INSTALLATION

After checking to be sure you have all required components and accessories (see Section II), proceed as follows:

A. HOSE AND ELECTRICAL CONNECTIONS

1. Connect shielding gas supply hose to the rear panel of the feeder.
2. Connect the 19-pin control cable between the DuraDrive rear panel and power source wire feeder connection.
3. Connect suitably sized power cable between the power source and the power block at the rear base of the feed-
er.

B. CENTER AND OUTLET GUIDES

The DuraDrive 4-30 feed is supplied with .035/.045" "V" groove feed rolls, outlet guide and center guide. Use the procedure
below if alternate accessories are required.

1. Referring to figure 4-1, choose the correct type and size center and outlet guide from Table 4-1.
2. Insert the center guide into the drive stand center support between the front and rear drive axles. Tighten the
locking knob to secure in place.
3. Insert the outlet guide tapered end first into the front of the MIG gun adapter and secure with locking knob.

C. MIG GUN CONNECTIONS (Gun Master 250 and 400)

1. Connect MIG Gun to feed roll accessory drive by loosening the locking knob on the side of the drive roll accessory
gun adapter and insert the gun power pin into the gun adaptor then tighten locking knob.
2. Connect the gun trigger twist lock plug into the mating receptacle on the front panel of the DuraDrive feeder and
lock by twisting 1/4 turn.

Table 2-1 - DuraDrive 4-30 Feed Roll Table

(4 req'd.)
0459052001
0459052003
0459052013
(4 req'd.)

(4 req'd.)

(1 req'd.)

(1 req'd.)

(1 req'd.)

25
SECTION 2 INSTALLATION
PRESSURE ROLL
BOGEY
cENTER GUIDE
UPPER ROLL cENTER
LOCKING KNOB
RETAINING KNOB GUIDE
PRESSURE
ADJUSTMENT
GUN LOCKING
KNOB

INLET GUIDE
LOCKING KNOB OUTLET
GUIDE

OUTLET GUIDE
LOCKING KNOB

INLET
GUIDE GEAR PIN
AXLE
LOWER ROLL
RETAINING NUTS

Figure 2-1 DuraDrive 4-30 Drive Stand

NOTE
The top roll arms are designed to equalized the pressure of each driven feed roll in order to optimize wire
feeding performance. DO NOT attempt to operate this drive system with only two drive rolls instead of the
recommended four drive rolls. Poor wire feed operation will result and possible damage and premature
wear of the gears driving the feed rollers.
D. INSTALLING FEED ROLL
Lower Feed Rolls
1. Release the tension lever on the pressure roll bogey and flip up to access the drive rolls
2. Remove the lower feed roll retaining knobs.
3. Separate the feed roll from the gear pin axle and slip the new feed roll on the gear shaft, engaging the gear pins.
4. Reinstall the feed roll retaining knobs.
Upper Feed Rolls
1. Release the tension lever on the pressure roll bogey and flip up to access the drive rolls
2. Remove the upper feed roll retaining knobs by turning knob 1/4 turn and pulling axle straight out.
3. Separate the feed roll from the gear pin axle and slip the new feed roll on the gear shaft, engaging the gear pins.
4. Reinstall the feed roll retaining knob and axle.

E. INSTALLING SPOOL OF WIRE

1. Remove “S-pin” clip from spindle.
2. Position the spool of wire so that when it is placed on the spindle, wire will be drawn to the feed roll from the bot­tom
of the spool. The spool should be held so that the index hole on the spool will engage the pin on the spindle.
3. Slide the spool onto the spindle until it engages the spindle pin. Lock in place with the S-pin clip.
4. Loosen the brake screw in the center of the spindle hub, then tighten it just enough to prevent coasting of the spool
when wire is drawn from it. Too much pressure will load the wire feed motor unnecessarily. Too little pressure will
permit the spool to overrun, causing the wire to come loose and tangle.

Do not allow metal‑to‑metal contact between the wire feeder chassis and a metal surface connected
in any way to a welding ground. With such contact, a poor welding ground connection may create
a difference in potential that sends part of the weld­ing current through the safety ground wiring in
the control cable and wire feeder, resulting in burnout of that wiring and/or damage to wire feeder
circuitry. If the safety ground burns out, the opera­tor may be exposed to electrical shock hazard.
26
SECTION 2 INSTALLATION

5. Thread wire to gun as follows:

a. Round off the free end of the welding wire with a file.
b. Release the tension lever to relieve pressure on the feed rolls. Rotate pressure adjusting knob off the pres-
sure roll bogey and lift bogey upward to access the feed rolls.
c. Thread the wire through the inlet guide, over the feed roll grooves in the feed rolls, and into the outlet
guide.
d. Lower the pressure roll bogey to engage the wire making sure the wire is seated in both the lower and upper
feed roll grooves.
e. Remove nozzle and contact tip from the gun. Turn on the Power Source using the main power switch and
then turn on the DuraDrive feeder by moving the Power Toggle switch to the "ON" position Inch the wire
using the DuraDrive jog switch until the wire exits from the front end of gun. Thread the contact tip over the
wire and tighten in tip adapter. Replace gun nozzle.
6. When wire coils are to be used, raise the spindle assembly to its highest mounting position in the spindle post.
Mount the wire reel onto the spindle as though it were a spool (see 1 and 3 above). Remove wing nuts and cover
plate from reel. Remove coil from its package, but do not remove its bind­ing wires or straps. Slide coil onto reel
so that wire will be drawn from bottom of coil (starting end for a coil is always the outer end). Replace reel cover
plate and wing nuts. Cut off coil tie wires. Adjust brake screw and thread wire to the gun as covered in 4 and 5
above.

F. ADJUSTING THE PRESSURE ROLL ASSEMBLY

When a new wire size or type installed, set the pressure adjustment as follows:
1. Unscrew the pressure adjustment knob until the pressure knob is free.
2. Alternately press and release the gun trigger switch while slowly tightening the pressure adjusting knob until the
wire begins to feed with­out slipping. The pressure applied should be the minimum required to provide positive,
nonslip wire feed. Too little pressure will result in wire slippage while ex­cessive pressure will scar and deform the
wire.

27
SECTION 2 INSTALLATION

28
SECTION 3 OPERATION

3.0 ADJUSTMENTS AND OPERATION

Make sure safety glasses with side shields are worn when handling or changing wire, or clip­ping
wire off at the spool or at the end of the gun‑serious eye injury can result due to the springiness of
the wire which quickly unravels, or a cut wire end which may shoot across the room.

NOTE
If the Trigger Lock option has been installed and set to the "ON" position, the trigger switch lever can be
released when the arc has been struck. Depress the trigger lever a second time to stop the arc. If the gun
is withdrawn from the workpiece during welding, the arc will be interrupted and wire feeding will stop
automatically. Dual schedule parameter switching from the gum trigger is disabled when TRIGGER LOCK
is turned "ON".

A. CONTROL SETTINGS
1. Turn the Main Power Switch on the front panel to the “ON” position.
2. Set the wire feed rate by adjusting the WIRE SPEED con­trol knob on the MMI panel. The wire feed rate, in turn,
controls the current furnished by the CV power source.
3. Set the Burnback control on the rear panel to the de­sired setting depending on the amount of burnback de­sired.
The higher the setting, the greater the amount of time that the contactor is held in to allow the wire to burn­back
out of the puddle, after releasing the gun trigger switch.

B. FEEDING WIRE
If wire has been threaded through gun and contact tip as directed in Sec. IV‑D‑5, simply operate the jog switch or cut off
wire, as required, so that the wire extends about 1/2­in. beyond the end of the gun nozzle.

C. SHIELDING GAS FLOW RATE

Actuate the gas purge switch and set gas flow rate at the shielding gas regulator‑flowmeter to 35 to 40 cfh. Maintain flow
for at least 15 seconds to insure adequate purging of gas hose and gun. If preflow/postflow option has been installed, set
its control knobs for the desired preflow and postflow intervals.

D. SLOW RUN-IN SWITCH

Set the Slow Run-in switch to the "ON" position if a slow run-in of the weld wire is desired. The wire feed speed will then be
at 1/2 the preset wire feed rate when the gun trigger is pulled until the arc is struck. The wire speed will then increase to
the preset speed for welding. This functions gives smoother arc starting for some weld applications.

E. MAKING THE WELD

Start to weld by pressing the gun trigger lever. This closes the welding contactor, and starts gas flow and wire feed. When
the welding wire touches the workpiece an arc will be established. The trigger switch lever must be depressed for the dura-
tion of the weld (unless the trigger latch option has been installed and set in the trigger latch position). Welding action will
be stopped and all services discontinued when the trigger switch lever is released and returns to its original position. If the
gun is withdrawn from the workpiece during welding, the arc will be interrupted, but shielding gas flow and welding wire
feed will continue until the switch lever is released.

F. CHANGING WIRE FEED MOTOR SPEED RANGE

The DuraDrive 4-30 wire feeder is shipped from the factory set for the 50 to 700 ipm (inches per minute) speed range. If
your typical wire feed speeds are close to the 600 to 700 ipm range, switching to the 350 to 999 ipm rate will provide better
resolution of the speed control knob and less sensitivity when setting welding parameters or adjusting arc length.

29
SECTION 3 OPERATION

To change the wire speed range to 350 to 999 IPM refer to Figures 3-1 & 3-2:
1. Turn the power "OFF" to the wire feed by moving the main power toggle switch of the front panel of the DuraDrive
feeder to the "OFF" position.
2. Remove the right side panel of the DuraDrive Control cabinet.
3. Locate switch SW-1 on the DuraDrive Control PCB.
4. Move dip switch S2 to the "ON" (CLOSED) position. Dip switches S1 & S3 should remain in the "OFF" position.
5. Replace the feeder side panel, turn the power switch "ON",
and reset wire feed speed.

Figure 3-1 Figure 3-2

Speed Range 50 to 700 ipm Speed Range 350 to 999 ipm
(factory setting)

G. Disabling the Gun Trigger Schedule Switching

The DuraDrive wire feeder is shipped from the factory set to enable switching to a second schedule with the gun using
the “Click Click” trigger technique, where the gun trigger is released and depressed quickly (within 0.2 sec). A wire feeder
equipped with a Dual Schedule MMI panel will switch to the alternate schedule.

If it is desired to disable the gun trigger schedule switching feature, do the following:

1. Turn the power "OFF" to the wire feed by moving the main power toggle switch on the front panel of the DuraDrive
feeder to the "OFF" position.
2. Remove the right side panel of the DuraDrive Control cabinet.
3. Locate switch SW-1 on the DuraDrive Control PCB. See Figure 3-3.
4. Move dip switch S1 to the "ON" position.
5. Replace the feeder side panel and turn the power switch "ON".

Power source contactor becomes energized the moment the gun trigger is depressed. Arcing can
occur if the wire is brought to a ground. Keep the gun away from ground until welding is to begin.

Figure 3-3
Disable Gun Trigger
Schedule Switch Feature

30
SECTION 3 OPERATION

Do not allow metal‑to‑metal contact between the wire feeder chassis and a metal surface connected
in any way to a welding ground. With such contact, a poor welding ground connection may create
a difference in potential that sends part of the weld­ing current through the safety ground wiring in
the control cable and wire feeder, resulting in burnout of that wiring and/or damage to wire feeder
circuitry. If the safety ground burns out, the opera­tor may be exposed to electrical shock hazard.

NOTE
The time setting can be overridden by releasing the gun trigger switch at any time during the weld.

3.1 OPERATING SEQUENCE

NORMAL
1 . Close gun trigger switch.
— Gas solenoid opens, weld contactor closes, wire feed motor runs at preset wire feed speed, or slow run-in, which-
ever has been selected.
2. Release gun trigger switch.
— Wire feed motor de-energized, brake circuit enabled.
— Anti‑stick circuit energized.
— Weld contactor opens.
— Burnback circuit times out
(delay determined by setting of Burnback potentiometer).
— Gas solenoid valve closes. Default post flow time is 2-1/2 seconds.

Spot Weld (Option Installed)

I . Close gun trigger switch.
— Gas solenoid opens, weld contactor closes, wire feed motor runs at preset wire feed speed, or slow run-in, which-
ever has been selected.
— Spot weld timing circuit energized. The timer is not activated until the arc is established. This guarantees the spot
times are consistent.
2. Spot weld circuit times out (interval established by setting of spot weld potentiometer).
— Wire feed motor de-energized, brake circuit effective. Burnback circuit energized.
3. Burnback circuit times out (interval established by setting of Burnback potentiometer).
— Weld contactor opens.
4. Release gun trigger switch.
— Gas solenoid valve closes.

Trigger Lock Weld (Option Installed)

I . Close gun trigger switch, wait until the arc is established and then release the gun trigger.
— Gas solenoid opens, weld contactor closes, wire feed motor runs at preset wire feed speed or Slow Run-In which-
ever has been selected.
— The trigger lock circuit will only become engaged if the arc has been established. If the gun trigger is released
before the arc is established the wire will stop feeding.
2. The arc can be terminated by two different methods.
A. Method #1 - Press the gun trigger switch
— Wire feed motor de-energized, brake circuit effective. Burnback circuit energized.
B. Method #2- Break the arc by pulling the gun away from the work.
— Wire feed motor de-energized, brake circuit effective. Burnback circuit energized.

31
SECTION 3 OPERATION

32
SECTION 4 MAINTENANCE

4.0 MAINTENANCE

If this equipment does not operate properly, stop work immediately and investigate the cause of the malfunction.
Maintenance work must be performed by an experienced person, and electrical work by a trained electrician. Do not
permit untrained persons to inspect, clean, or repair this equipment. Use only recommended replacement parts.

A. GENERAL MAINTENANCE

Little maintenance is required to keep the wire feeder in top operating condition. It is important, however, that moving parts
such as feed and pressure rolls, wire feed motor, etc., be kept clean and free of dust or dirt. Cleaning is best accomplished
by regularly blowing off these parts with dry compressed air. This should be done once for every eight hours of operating
time, more often if necessary.

33
SECTION 4 MAINTENANCE

34
SECTION 5 TROUBLESHOOTING

5.0 TROUBLESHOOTING

Refer to the troubleshooting Chart Table 5-1.

Table 5-1 - DuraDrive 4-30 TROUBLE SHOOTING CHART

35
 D-0558002964-C

36
DuraDrive 4-30 Schematic Diagram
SECTION 5 TROUBLESHOOTING
 D-0558002965-B

37
DuraDrive 4-30 Wiring Diagram
SECTION 5 TROUBLESHOOTING
SECTION 5 TROUBLESHOOTING

38
SECTION 6 REPLACEMENT PARTS

6.0 SPARE AND REPAIR PARTS

Replacement Parts are illustrated on the following pages. When ordering replacement parts, order by part number and part
name, as illustrated on the figure

Always provide the series or serial number of the unit on which the parts will be used. The serial number is stamped on the
unit nameplate.

6.1 ORDERING

To assure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment.
The use of non-ESAB parts may void your warranty.

Replacement parts may be ordered from your ESAB distributor or from:

ESAB Welding & Cutting Products

Attn: Customer Service Dept.
P.O. Box 100545, 411 S. Ebenezer Road
Florence, SC 29501-0545

Be sure to indicate any special shipping instructions when ordering replacement parts.

To order parts by phone, contact ESAB at 1-843-664-5540. Orders may also be faxed to 1-800-634-7548. Be sure to indicate
any special shipping instructions when ordering replacement parts.

Refer to the Communication Guide located on the last page of this manual for a list of customer service phone numbers.

39
SECTION 6 REPLACEMENT PARTS

122 18, 24

24, 93

22, 69, 80 98 89

86, 87

79

40
SECTION 6 REPLACEMENT PARTS

25, 28

84, 85 10, 11 31, 32

4 9, 82

71

26
12, 30

8, 9 13 12, 30 6 18, 24

41
SECTION 6 REPLACEMENT PARTS

75
29
16 104

92

67

119

1
105 3, 66, 83 5 2

42
SECTION 6 REPLACEMENT PARTS

78
15 74
81

23
2

100 99

112
102

2
96
103

95

91

20

21 101
111

73

17
33

34

76, 77, 90
19

97
78
7, 109
14 94
7

43
SECTION 6 REPLACEMENT PARTS

950626 13.3

44
SECTION 6 REPLACEMENT PARTS

Items marked with * are: Screw, .375-16 x 1.00" Lg., RH and Washer, .375" Flat

45
SECTION 6 REPLACEMENT PARTS

46
SECTION 6 REPLACEMENT PARTS

47
SECTION 6 REPLACEMENT PARTS

48
SECTION 6 REPLACEMENT PARTS

2
3

NOTE: For replacement of new module include Item 8.

49
Notes
 Revision History

1. Revision “A” edition (1/2002) of the manual covers the following changes:

Updated and corrected Optional Accessories listed on page 16.

2. Revision "B" edition (2/2002) of the manual covers the following changes:

Updates images on page 21 to show a better view of switch settings.

3. Revision "C" edition (3/2002) of this manual covers the following changes:

Updates Accessories listing on page 16 and Replacement Parts listing on page 31.

Updated Replacement Parts section.

4. Revision "E" edition (11/2003) of this manual covers the following changes:

Changed the replacement parts for the clamp, P/N 952860 to P/N 950626 1 ear 13.3 GER. Various editorial changes
were also made.

5. Revision "F" edition (01/2004) of this manual covers the following changes:

Updated the Schematic (0558002964) and Wiring Diagram (0558002965) pages in Troubleshooting section to latest
revision.

6. Revision "G" edition (02/2004) of this manual covers the following changes:

Updated Table 2-1 with revised part numbers for Solid Wire V Groove.

7. Revision "H" edition (06/2008) of this manual covers general text/illustration changes per John Magee.
 ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS:

Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST
Order Entry Product Availability Pricing Order Information Returns

B. ENGINEERING SERVICE:
Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting

C. TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM EST
Part Numbers Technical Applications Specifications Equipment Recommendations

D. LITERATURE REQUESTS:
Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS:

Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM EST
Repair Estimates Repair Status

F. WELDING EQUIPMENT TRAINING

Telephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM EST
Training School Information and Registrations

G. WELDING PROCESS ASSISTANCE:

Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:

Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123

Fax: (843) 664-4462
Hours: 7:30 AM to 5:00 PM EST
or
visit us on the web at http://www.esabna.com
The ESAB web site offers
Comprehensive Product Information
Material Safety Data Sheets
Warranty Registration
Instruction Literature Download Library
Distributor Locator
Global Company Information
Press Releases
Customer Feedback & Support

F15-635-H 06 / 2008